Interlocking uniformly vertically scalable thermoformed food packaging (suitable for chocolates)

ABSTRACT

An easily assembled, two-component, scalable solution for packaging and presenting varying quantities of chocolates (or any uniformly sized food product). The use of food-grade thermoformed plastic creates a simple, safe, and compliant packaging solution for food items that may be purchased in variable quantities. The combination of transparent or translucent plastic, slanted pockets, and stackable trays, creates a unique and aesthetically pleasing product presentation. Design features such as bevels, matching insets/outsets, and locking dimples ensure a rigid and robust assembly, regardless of quantities packaged. The use of food-grade plastic combined with the unique package design eliminates the need for other packaging materials (e.g. candy cups, inserts, pads, setup boxes, etc.) simplifying the packaging requirements and reducing the overall cost of production, assembly and packaging.

CROSS REFERENCES TO RELATED APPLICATIONS

Not Applicable

FEDERALLY SPONSORED RESEARCH & DEVELOPMENT

Not Applicable

PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

MATERIALS SUBMITTED ON A COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

A design for packaging using food-grade thermoformed plastic to create standard components that can be variously assembled to create a scalable set of like packaging solutions. The design has specific unique elements designed to address issues caused by scalability and standardization and thus results in a uniform “look and feel” regardless of number of units packaged.

The design was initially conceived as a chocolate packaging solution for individual chocolate pralines as a result of the shortcomings of existing commoditized chocolate packaging. However, in overcoming some of the design challenges, the inventor realized that the basic design elements described herein could be applied to any application requiring the scalable packaging of standardized units.

2. Related Art

Most packaging of individual chocolates is in food-grade cardboard boxes. Additional inserts are generally required and may be individual paper “candy cups”, card dividers or thermoformed plastic trays. Candy pads are also often required. Other forms of packaging include cellophane bags, folded clear plastic boxes, folded card envelopes, foil wrap, and vacuum sealed wraps of various materials.

This invention introduces the concept a simple standardized method of packaging varying quantities of chocolate using only food-grade thermoformed plastic. While food-grade plastic packages are currently manufactured, they tend to be folded and glued plastic boxes, with no design consideration for the internal setting of the chocolates (i.e. additional inserts as described above are required).

In addition, readily available commoditized chocolate packaging assumes 1″ (one inch) high pralines and the inventor wishes to create a solution for ½″ high pralines. While this is a specific industry problem regarding related art, it is not a specific constraint on this design—which can be manufactured for any sized chocolate of any form (praline, truffle, etc.)

BRIEF SUMMARY OF THE INVENTION

A food packaging design for packaging uniform units in scalable quantities using only two basic components—a “tray” form and a “lid” form.

A food packaging design for packaging uniform units in scalable quantities using collections of stackable standard trays.

A food packaging design for packaging uniform units in scalable quantities that uses the intentional application of beveled edges, combined with specific dimension ratios, to overcome several design challenges in creating a uniform, scalable and practical packaging solution (as detailed in the “Claims” section).

A food packaging design for packaging uniform units in scalable quantities that can be executed using food-grade thermoformed plastic for specific application to the packaging of chocolate pralines or, generally, for any uniformly sized food unit.

A tray design that displays chocolates using a slanted pocket. (This design element is independent of, and not essential to, the other more general design concepts described herein. It represents a specific implementation that the inventor wishes to use in chocolate packaging).

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The example illustrated uses 1/32″ (one thirty-secondth of an inch) food-grade thermoformed plastic to create a packaging solution for 1″ (one inch) by 1″ (one inch) by ½″ (half inch) chocolate pralines. However, the specific dimensions shown may be modified by the engineering and tooling process, so they should be viewed as indicative only.

In addition, the design concept is applicable to product dimensions other than that illustrated. Utility Patent protection is therefore requested for both the specific chocolate packaging design specified (which the applicant believes is unique in the chocolate industry) and the more general design elements and concepts embodied.

FIG. 1: BASIC ASSEMBLY

Shows basic assembly for a two-tray package (8 chocolates). Multiple trays can be assembled to create a scalable package (e.g. 4, 8, 12, 16 chocolates, etc.)

-   -   2 (two) basic components—“tray” and “lid”—create multiple         (scalable) parts to the box assembly.     -   Stacking is aided by bevel on top of tray.     -   Locking is aided by male and female dimples.     -   Top lid finishes package.     -   Slanted candy pockets allow for storage of 4 (four) chocolate         pralines per tray.

FIG. 2: TRAY PERSPECTIVES

Shows 3D perspective of “Chocolate Praline” Tray with key design elements.

-   -   The tray is only created in a single form—scalable storage of         multiple units is accomplished by stacking multiple trays.     -   Side indent/overlap is the same width as the plastic used (used         1/32″ in spec) which allows clean finish of stacked trays and         lid.     -   Top dimple is female, bottom dimple is male.     -   Slanted pockets support pralines without enveloping them,         providing better display.     -   Bevels provide for easier stacking and better finished package.

FIG. 3: TRAY SPECIFICATIONS

Shows specifications for a 4 (four) praline tray manufactured from 1/32″ thermoformed food-grade plastic.

FIG. 4: TRAY SPECIFICATIONS—POCKET CROSS-SECTION

Shows a side-view vertical cross-section cut mid-way through two chocolate pockets.

-   -   Top opening of pocket is 1¼″×1¼″ (one and a quarter inch) to         allow for natural variance in 1″×1″ (one inch) pralines.     -   Pockets are slanted and less deep than the praline in order to         provide aesthetic display of product.     -   ¼″ (quarter inch) internal pocket rim allows for easy insertion         and removal of chocolates.     -   Design and dimensions of side walls provide for stack-ability         for ½″ (half inch) high pralines.

FIG. 5: LID SPECIFICATIONS

Shows lid features and dimensions.

-   -   Inside dimensions of lid equal outside dimensions of tray top.     -   Bevels provide neat finishing of package, consistent with tray         design.     -   Male dimples lock lid to female dimples in tray top, allowing         for tight assembly.

DETAILED DESCRIPTION OF THE INVENTION

Most packaging of individual chocolates is in food-grade cardboard boxes. Trays may be individual paper “candy cups”, card dividers or thermoformed plastic trays. Other forms of packaging include cellophane bags, folded clear plastic boxes, uniquely designed folded card lids, foil wrap, and vacuum sealed wraps of various materials.

This invention introduces the concept a simple standardized method of packaging varying quantities of chocolate using only food-grade thermoformed plastic. In overcoming some of the design challenges, the inventor realized that the basic design elements could be applied to any application requiring the scalable packaging of standardized units.

Some unique aspects of this design are elements that overcome the challenges presented by using thermoformed plastic, which requires a pressed form resulting in sharp edges and opposing profiles (e.g. a “finished” top profile and an “open” bottom profile).

These challenges include:

-   -   1. Minimizing the number of components required for manufacture,         due to the tooling and set-up costs involved (each form requires         a $10,000-$20,000 investment)     -   2. Creating a “finished” package that would be acceptable for         retail and wholesale merchandizing, that is also a unique and         attractive solution     -   3. Ensuring consistent scalability without altering the basic         design (“look and feel”)     -   4. Providing for ease of use and assembly     -   5. Ensuring safe handling

The inventor has designed a solution that uses only 2 (two) basic elements. The more complex form (the “tray”) need only be manufactured in one size and can be stacked to support the packaging of different quantities of units (e.g. chocolates). The simple (less costly) form (the “lid”) is designed to create a finished package (regardless of number of chocolates packaged).

The use of beveled edges in both the tray and lid allows for easy, consistent assembly and a safer more aesthetically pleasing end-product, while the application of wall insets/outsets and locking dimples ensures fit, structural rigidity, and uniformity in different sized packages.

These design elements also promote safe handling. The bevels minimize sharp edges and reduce “fiddling” while inserting one component over another, while the locking dimples prevent already assembled components separating unintentionally—spilling product.

While not essential to the core design concept, the use of slanted pockets (as shown in the diagrams) within the translucent package creates a more interesting unit display. The inventor also believes (to be validated by an engineer) that the use of bevels and slanted pockets increases the structural rigidity of the tray.

The design was conceived due to deficiencies in existing chocolate packaging (prior art):

-   -   1. Commodity candy boxes and packaging can be purchased at a         reasonable price point. However, they assume a typical praline         depth of 1 (one) inch. The inventor will be producing pralines         that are no more than ½ inch deep, so choices in commoditized         packaging are limited (non-existent for practical purposes).     -   2. Customized packaging usually entails the creation of custom         cardboard setup boxes with custom trays and fillers. The         cumulative cost of these can be from $3 to $6 a box—which is a         significant cost of sale. Generally, due to cost, these boxes         would be reserved for wholesale and not for point-of-sale         packaging.

While there is an up-front cost in developing the molds for the solution described herein, it provides an ongoing cost-effective, unique and scalable solution for both wholesale and point-of-sale packaging. For the initial 50,000 run, about 10 cents a chocolate and subsequent runs about 2 cents a chocolate.

The inventor strongly believes this solution will be attractive to other chocolate wholesalers and retailers and minimally seeks patent protection related to chocolate packaging. The inventor believes the design principles are sufficiently unique to warrant patent protection for generalized application, if such request does not negatively affect the specific claim. 

1. The invention is an original concept, design and implementation for food packaging not existing in prior art, comprising of: a “tray” made of thermoformed plastic that may contain various quantities of chocolate pieces (or other uniformly sized food items) depending on design preference (example herein containing four pieces) that can be vertically assembled in various quantities to create a scalable packaging solution that is completed by a capping with a matching “lid” made of like material.
 2. The concept and design described in claim 1 is a simple and cost-effective solution for chocolate packaging (or any uniformly sized items that may be purchased in variable quantities), consisting of: only two components that can be mass-produced using thermoforming.
 3. The concept and design described in claim 1 allows for component reuse in the implementation of a “vertical scalability” concept that is a unique and elegant alternative to the shortcomings of prior art (typically, many different sized chocolate boxes and inserts must be manufactured to support different quantities to be packaged, each component having a significant tooling and set-up cost), consisting of: standardized, interlocking, tooled, shapes.
 4. The invention implements elements that are uniquely designed and specified to support scalable assembly, comprising of: thermoformed plastic shapes containing specific ratios of dimensions; corner beveling; wall insets/outsets; locking dimples.
 5. The invention is distinguished from prior art by supporting the assembly requirements regardless of the scale of package assembled, through the intentional application of the unique design elements described in claim 4, comprising of: assembled package uniformity; component matching; fit; ease of assembly; structural rigidity; safe handling.
 6. The invention creates a package having an original aesthetic and utility unique in the chocolate packaging industry through an original combination of design and materials, comprising of: scalable package design; transparent or translucent food-grade thermoformed plastic; slanted pockets.
 7. The invention displays chocolates (or other uniformly sized food products) in a unique manner (relative to prior art) due to the original aesthetic and utility described in claim 6, consisting of: a uniformly scalable, vertical assembly concept (traditional chocolate packaging tends to scale horizontally, non-uniformly).
 8. The invention displays chocolates (or other uniformly sized food products) in a unique manner (relative to prior art) due to the original aesthetic and utility described in claim 6, consisting of: a three dimensional view of the slanted pockets enabled by the use of transparent or translucent plastic.
 9. The invention creates economy and utility by eliminating the need for other packaging materials (e.g. candy cups, inserts, pads, setup boxes, etc.), thus simplifying the packaging requirements and reducing the overall cost of production, assembly and packaging (relative to prior art) due to the original aesthetic and utility described in claim 6, consisting of: the use of food-grade, thermoformed plastic in a fully integrated design. 